Use a table-mounted router and flush trim bit with bearing?
Brian
Brian
I hope this helps,mcbradford said:I'm sorry but I am having trouble understanding what you have done and what you are trying to do.
Let me see if I'm at least close. You started with a piece of plexiglas and used that to make a template. The template looks like a square/rectangle with a "X" cut out of it. This "X" is what you now want to run a guide bushing in and the bit will cut the shape of an "X" into the finished project.
The 1/8" material is thinner then the guide bushing barrel height so now I'm really lost.... how do you keep the router sub-base on the template and have the bushing not touching the project material? Or is this where the problem starts? If this is what is happening then what you need to do is find out how long the barrel of the template guide is then use some material cut to ruffly the shape of the "X" but larger and it does not need to be accurate. Attach this material to the template you have made... to the under side would be best. I might be way off on what you are asking so I will not continue but if I am on track and you need more information post again and I'll finish the story.
I took a piece of 1/8" plexiglas and used my router (along with the router guide from rockler). The template turned out perfect. I cannot get a good clean cut however. My router edge get stuck on the corners of the oposite side of the "X". I often over-shoot the edges.
Should I used thicker plexiglas? I though about using a larger router base, this would float over the entire template.
I have been using double-stick tape to hold down my piece I am cutting. I drilled/counter sunk four holes on the template, to secure with screws.
Any suggestions?